Liquid reservoir system and method

ABSTRACT

Liquid reservoir systems are disclosed. In one embodiment, a liquid reservoir system may capture and retain a fuel reservoir to provide an uninterrupted fuel supply to a fuel pump or pickup line during low fuel conditions such as those that may be experienced during vehicle acceleration, braking or side to side maneuvers. It may also capture and retain a fuel reservoir to provide an uninterrupted fuel supply to a fuel pump or other pickup line during periods of high agitation such as may be experienced during vehicle jumping, cross country/closed course racing and other aggressive driving maneuvers.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/076,718, filed Nov. 7, 2014, the disclosure of which isincorporated, by reference, in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to liquid reservoir systems thatprovide fluids/liquid to a mechanical or electric pump.

2. Description of Related Art

Many existing fuel delivery reservoir systems rely on a jet pump tosweep fuel from the fuel tank to fill the reservoir by virtue of thesiphon effect. This reservoir fuel is then used to supply the fuel pump.The jet pump uses the pressurized discharge fuel from the electricalfuel pump and/or the discharge of the fuel pressure regulator. Duringsome driving conditions, such as centripetal/centrifugal and/or otherpositive or negative gravitational “G” forces caused by turns rapidacceleration/deceleration, rapid elevation change and/or angularorientation change events can move fuel away from the jet jump,preventing the jet pump from pumping more fuel into the fuel reservoir.When the limited supply of fuel in the reservoir is depleted, the fuelpump cannot pump fuel to the engine, and the engine may stall from lackof fuel, even though there is fuel in the fuel tank.

Some other existing fuel delivery reservoir systems try to remedy theloss of fuel being provided to the fuel reservoir by using baffles toform a wall around the fuel pump in an attempt to hold a portion of thefuel near the pump inlet. However, this only slows the movement of fuelaway from the pump inlet by virtue of one-way flaps or other means tocapture fuel. This approach does not use a syphon jet so it is limitedto the fuel level in the tank, and cannot keep the available fuel at alevel above the pump inlet indefinitely. This method relies on somealternate motion of the vehicle to “slosh” the fuel back through thebaffled openings into the fuel reservoir. Since the baffle flaps seal bytheir own weight, their effectiveness is consistently poor.

SUMMARY OF THE INVENTION

Liquid reservoir systems are disclosed. In one embodiment, a liquidreservoir system may capture and retain a fuel reservoir to provide anun-interrupted fuel supply to a fuel pump or pickup line during low fuelconditions such as those that may be experienced during vehicleacceleration, braking or side to side maneuvers. It may also capture andretain a fuel reservoir to provide an un-interrupted fuel supply to afuel pump or other pickup line during periods of high agitation such asmay be experienced during vehicle jumping, cross country/closed courseracing and other aggressive driving maneuvers.

In one embodiment, a liquid reservoir system may capture and retains afuel reservoir to ensure that all available fuel in the larger fuel tankis absorbed, captured and consumed, which may extend the time betweenracing pit stops and refueling times.

In one embodiment, a plurality of liquid reservoir systems may beconnected in series so that each reservoir may capture and feed fuelwhen fuel is available, but may be sealed off when fuel in that arearuns dry.

In another embodiment, liquid reservoir system 600 may be used insaddle-tank applications using, for example, a transfer tube.

In one embodiment, a liquid reservoir system may move fuel from a lowerportion of the tank or a saddle tank to the actual pump location.

In one embodiment, a liquid reservoir may provide fuel when a vehicle(e.g., aircraft) is inverted, may be inverted, or is recovering frombeing inverted.

In one embodiment, a liquid reservoir may assist in blocking,eliminating, and/or excluding air bubble intrusion into main fuel feedline.

In one embodiment, a liquid reservoir may act as a pre-filter before thefuel pump.

In one embodiment, a liquid reservoir may act as a “dual reservoir”providing extended protection in extreme situations.

In one embodiment, a liquid reservoir may work with any liquid having asufficient surface tension and wicking ability. The liquid reservoir mayhave a variety of applications, including vehicle, aircraft, boating,military, etc.

In one embodiment, a liquid reservoir may have any suitable shape thatis conducive to being inserted thru a small hole, such as an “x” shape,spider shape, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

Purposes and advantages of the exemplary embodiments will be apparent tothose of ordinary skill in the art from the following detaileddescription in conjunction with the drawings in which like referencecharacters are used to indicate like elements, and in which:

FIG. 1 is an isometric plan view of an embodiment of a liquid reservoirsystem installed in a fuel tank with and internal fuel sender assemblyaccording to one embodiment.

FIG. 2 is an isometric cutaway view of a liquid reservoir systemaccording to one embodiment.

FIG. 3 is a cross section view of a liquid reservoir system having anoutlet port according to one embodiment.

FIG. 4A is a schematic side view of the a liquid reservoir systemshowing embodiments of return fuel line configurations.

FIG. 4B is a schematic showing multiple suction points feeding a singleoutlet hose according to one embodiment.

FIG. 5A is a schematic top view of a liquid reservoir system including afuel retainer according to one embodiment.

FIG. 5B is a schematic side view of the liquid reservoir system of FIG.5A.

FIG. 6 is an illustration of a liquid reservoir system according to oneembodiment.

FIG. 7 is a sectional view of the liquid reservoir system of FIG. 6.

FIG. 8 depicts an exemplary shape for a liquid reservoir system.

FIG. 9 depicts an liquid reservoir system that includes an externalreservoir according to one embodiment.

FIG. 10 is a sectional view of the liquid reservoir system that includesan external reservoir of FIG. 9.

FIG. 11 is an exemplary external reservoir.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is intended to convey a thorough understandingof the embodiments by providing a number of specific embodiments anddetails involving a liquid reservoir system. It is understood, however,that the invention is not limited to these specific embodiments anddetails, which are exemplary only. It is further understood that onepossessing ordinary skill in the art, in light of known devices, systemsand methods, would appreciate the use of the invention for its intendedpurposes and benefits in any number of alternative embodiments.

In any type of pumping system, providing a constant, uninterrupted flowof liquid to the pumping device is imperative for optimum performance,pump longevity and pressure consistency. When the supply of liquid isinterrupted, air pockets may be ingested by the respective pumpingsystem. These air pockets will cause pressure drops/spikes, cavitation,aeration of the liquid, undesirable noise, possible pump damage (if thepumped liquid also serves as a pump lubricant), and higher pumpoperating temperatures.

In any device where the liquid pump operates in an environment where theflow of liquid may be interrupted (e.g., by low liquid levels, externalforces such as centrifugal forces), there is a benefit to a device thatcaptures the incoming liquid and retains the liquid so that it can bepresented to the inlet of the pump in an uninterrupted manner until thereservoir/tank is completely empty or normal reservoir levels arerestored.

One specific use of the devices disclosed herein is inautomotive/vehicle fuel tanks. Early fuel tanks that were designed forcarbureted vehicles had a simple pick-up tube that extended down intothe tank and served as an inlet for the engine-mounted mechanical fuelpump. During normal cornering with low fuel levels, the pick-up tubebecomes uncovered, allowing air to enter the fuel system. This was not asignificant problem as the engine continued to run using the fuel thatwas retained in the carburetor float bowl until normal fuel flowresumed. Air that was present in the float bowl was naturally vented tothe atmosphere.

Many of these vintage vehicles, however, have been converted toelectronic fuel injection. When the conversions are done, many peopleretain the stock type fuel tank and use an in-line fuel injection pump.This may create several issues as there is no longer a reservoir of fuelkept in the carburetor because the carburetor has been removed. Forexample, the vehicle may stall as soon as the fuel pick-up tube isuncovered (due to air entry into the fuel pump), leading to poorperformance and possibly dangerous situations. Moreover, there is nomechanism to vent air—once in the system, the air must be pushed throughthe injectors.

In modern vehicles, fuel systems have transitioned to fuel injectionwith fuel pumps mounted inside the tanks within “fuel modules.” Thesefuel modules utilize jet pumps to refill a reservoir from which the fuelpump is fed. This design is typically acceptable for OEM applications,but is insufficient for extreme applications often found in road racing,oval track racing, autocross, off-road racing, motorcycles, ATV's,snowmobiles, aircraft and other extreme applications.

According to embodiments, these and other shortcomings are addressed byproviding an uninterrupted supply of fuel/liquid to the pump inletthrough the use of a reservoir mat/blanket. The blanket activelycollects and retains liquid inside in its reservoir through scavenging,absorption, wicking, capillary action, and/or self-sealing action toexhaust the supply of the liquid in the tank before the liquid supply tothe pump is interrupted.

In one embodiment, while the present disclosure may be primarily in thecontext of a fuel environment, it should be recognized that thedisclosure is not so limited. The present disclosure may be used with avariety of fuels (e.g., gasoline, diesel, aircraft fuel (e.g., Jet-A,Jet-Propellant, etc.), biofuels, liquid propane, etc. It may be usedwith other liquids as well, for example, water, antifreeze, oil,chemicals, beverages (e.g., milk, juice, etc.).

In the following embodiments, the liquid reservoir system may provide areservoir of liquid, such as fuel, for a vehicle system. In addition, itmay draw the liquid to a pump or other vacuum source, such as a fuelpump, and may also prevent air from being drawn into the pump. It mayfurther filter the fuel.

In one embodiment, the liquid reservoir system may have some or all thefollowing properties. First, the depth media micron rating may be 15microns. The liquid reservoir system may be sized to reach criticalpickup areas with enough surface area to supply fuel system when tankgoes dry or fuel cannot be reached. The liquid reservoir system may beshaped based on size and on installation requirements (e.g., the size ofthe hole through which the liquid reservoir system will be installed).The internal volume may be selected to provide a safety cushion of fuelsupply if the tank is exhausted or run to a level where the pickupcannot reach fuel. The inlet configuration may be selected (e.g.,multiple inlets, fitting type, etc.) for the specific application.Internal baffling may be provided for high g-Force applications. Thepackaging may be application-dependent based on the tank's intended use,whether the tank has baffles or not, shape of tank and fluid dynamics oftank shape (e.g., wide/flat, tall/skinny, and saddle tanks (e.g., onetank with a “hump” in the middle) require different shapes), etc.Magnets and other retention devices may be used to secure the liquidreservoir system in one location in the tank.

Referring to FIGS. 1 and 2, an exemplary embodiment of liquid reservoirsystem 100 is provided. Liquid reservoir system 100 may be provided withinternal structure 120 that may provide structural rigidity to internalcavity/reservoir volume 130 in liquid reservoir system 100. Internalstructure 120 may be fully contained within enclosure 110, or includeexternal supports. Internal structure 120 may be made of fuel-compatibleplastics, composites, metals, other materials, and combinations thereof.

In one embodiment, internal structure 120 may be a cylindrical plasticmesh tube as shown in FIG. 2. In another embodiment, the internalstructure may be a half-cylinder made of plastic mesh. In anotherembodiment, internal structure 120 may comprise pieces of semi-circularplastic mesh. In another embodiment, internal structure 120 may comprisea plurality of pieces of semi-circular plastic mesh that may interactwith one another. In other embodiments, internal structure 120 may beshaped as a spring coil or other structural members such as struts,trusses, box frames and the like. In one embodiment, open-cell foam maybe used.

Internal structure 120 may be at least partially collapsible to allowinsertion and removal through small openings in a fuel tank 10, such assender assembly opening 200.

In one embodiment, port 140 may include flange 142 that may be coupledor otherwise adhered to top surface 113 of enclosure 110, as shown inFIG. 3. Port 140 may also include one or more standoff 146. Wheninstalled in a fuel tank, standoffs 146 may prevent suction and/or theweight of fuel pump 210 from collapsing internal structure 120 in orderto maintain a flow path for the fuel in liquid reservoir system 100 intofuel pump 210.

In one embodiment, port 140 may be designed to either couple directly toan inlet of internal fuel pump 210 by a press fit, threads, adhesiveand/or mechanical clamps. In another embodiment, port 140 may couple toa hose or tube that is connected to an external fuel pump (not shown).When coupled to an external fuel pump, port 140 may include a standardAN-type or external flare fuel fitting, inverted flare fitting, pipethread or hose barb.

Port 140 may be made of a plastic and/or a composite material and may beattached directly to top surface 113 or it may be secured mechanicallythru the wall of the reservoir using, for example, sealing washers andfasteners, or any other suitable securing mechanism or technique.

In one embodiment, internal structure 120 and port 140 may be moldeddirectly into and/or as part of enclosure 110 as a single piece liquidreservoir system 100.

In one embodiment, more than one port 140 may be provided. For example,ports 140 may be positioned on liquid reservoir system 100 in anylocation where the fluid may be located (or where it is expected to belocated) during low level conditions, due to centrifugal force, etc. Thesurface tension of the liquid may prevent air from being pulled from aport 140 that has no liquid present while another port 140 has liquidpresent.

For example, for a vehicle on a circle/oval racetrack, ports 140 may beprovided on the right-hand side of the liquid reservoir system 100. Fora vehicle on a road course, ports 140 may be provided on the left andright sides of liquid reservoir system 100, as well as in the middle. Ina saddle tank, a first port 140 may be provided on one end of the“saddle,” while a second port 140 may be provided on the other end ofthe “saddle.” The positioning may be determined based on the anticipatedforces to be experienced, and the one or more ports 140 may bepositioned on liquid reservoir system 100 as necessary and/or desired.

In one embodiment, multiple ports 140 may connect to the same pump or toa different pump. In one embodiment, the paths from ports 140 may bejoined within liquid reservoir system 100, or external to liquidreservoir system 100.

In one embodiment, fuel return line 240 a or 240 b of the senderassembly 200 may be directed to the bottom on the tank and thendischarge parallel to the liquid reservoir system 100 just above its topsurface 113, as shown in FIG. 4A. Direct impact of return fuel 245 a/bmay force vapor bubbles thru the media of the liquid reservoir system100 causing pressure fluctuations or complete pressure loss. The totalpressure loss can occur with a low fuel condition when there is morevapor bubbles in the return line due to generally higher fueltemperatures from the constant recirculation. The returned fuel 245 a/bhas been heated by the engine since a majority of the systems have theregulator in the engine compartment attached to the fuel injector railsor as close as possible to the carburetor(s). The higher the systempressure the more likely the returned fuel 245 a/b will have entrainedvapor bubbles during the transition from system pressure to atmosphericpressure in the return line.

FIG. 4A presents two embodiments of desirable fuel return lineconfigurations for the invention. Fuel return line 240 a is configuredto for easy installation through an existing tank opening with thesender assembly 200, but directs return fuel 245 a away from the fuelpump 210. Fuel return line 240 b is configured to direct return fuel 245b towards fuel pump 210, but may be more difficult to install.

In embodiments where top surface 113 is non-permeable, the non-permeablesurface may prevent vapor bubbles from being drawn through enclosure 110by protecting the immediate area near the discharge of the return fuelline 240 a/b.

FIG. 4B depicts an embodiment in which multiple suction points feed asingle outlet hose. For example, suction points 265A and 265B areprovided from liquid reservoir system 100 to pump 210. Fuel return line270 return fuel from the regulator and has multiple discharge points270A and 270B. This may be used to constantly wet the surface andprotect the surface tension as long as there is return fuel. This fuelmay then be pulled to the interior of liquid reservoir system 100 forreuse. In one embodiment, a separate return hose 270 may be provided toeach fuel suction point.

FIGS. 5A and 5B show another embodiment of liquid reservoir system 100including fuel retainer 150. Fuel retainer 150 may be box-shaped with anopen bottom adjacent to top surface 113 of liquid reservoir system 100.Fuel return line 240 enters through hole 153 in the top of fuel retainer150, discharging return fuel 245 into fuel retainer 150. Return fuel 245may then be readily accessible to fuel pump 210 through liquid reservoirsystem 100.

In one embodiment, fuel retainer 150 and/or hole 153 may be oversized toallow clearance around return line 240 to allow over flow fuel and/orentrapped air to escape. In another embodiment, fuel retainer 150 mayinclude one or more additional hole and/or top opening to allow overflow fuel and/or entrapped air to escape (not shown). In anotherembodiment, fuel retainer 150 may include flange 155 which may be bondedto top surface 113 of liquid reservoir system 100 by adhesives,ultrasonic welding, hot plate welding, or any other suitable bondingmeans.

In one embodiment, liquid reservoir system 100 may also draw or wickfuel, via capillary action or other means, from any area of the tankthat the liquid reservoir system reaches. In low fuel conditions thismay maintain a fuel supply to the fuel pump inlet regardless of the sizeand/or shape of the fuel tank floor. This may be extremely valuable asit enables all the fuel in the fuel tank to be available forconsumption. If one portion of liquid reservoir system 100 is in alocation devoid of fuel, liquid reservoir system 100 may draw fuel fromother locations where fuel is still accessible without ingesting air.The wicking ability of the media of the liquid reservoir system 100 mayalso reduce the need for the liquid reservoir system 100 to be incontact with the bottom of the tank, reducing the potential oftransferring vibration/noise from the fuel pump.

In one embodiment, the surface tension of the wetted media of the liquidreservoir system 100 may prevent air from being drawn through it untilsubstantially all the fuel is removed from liquid reservoir system 100by the fuel pump. At this point, the surface tension may be broken bythe air and the pump may ingest the air and lose fuel pressure.

In one embodiment, liquid reservoir system 100 may enable the fuel pumpto draw all the fuel from the tank before the media permits air to bepulled into the fuel pump, regardless of vehicle dynamics.

In one embodiment, liquid reservoir system 100 may have a very lowprofile which displaces less fuel then the conventional, complicatedmolded reservoirs or metal baffle designs currently in vehicles bothoriginal equipment manufacturers and aftermarket suppliers.

In one embodiment, liquid reservoir 100 may be a thin reservoir with asingle or thin layers of separation between the top and bottom media.This may minimize the ingestion of air so when additional liquid isadded to the tank (or the liquid returns) it will have less air for thepump to pull out of the interior before the liquid is available whichmakes for a faster recovery of liquid pressure from the pump.

In one embodiment, the shape of liquid reservoir system 100 may becontoured depending upon the fuel tank design to reach particular areasof the tank. For example, circle/oval track vehicles will constantlyforce the fuel to the right side of the tank as they drive in thecounterclockwise path. The liquid reservoir system can have a shape tofavor the right side where the fuel tends to stay.

In one embodiment, liquid reservoir system 100 may have no moving partsand is substantially lighter and displaces less fuel than otherreservoir and/or fuel access systems. The advantages are weight and/orcost reduction, and simplicity. This may permit more fuel in the sametank compared to other systems. For example, NASCAR fuel tanks have ahigh pressure pump that draws from a central reservoir. Additionally,there are multiple lift pumps that constantly draw fuel from remoteareas of the tank and transfer the fuel to the central reservoir. Thesemultiple pumps are agitating the fuel along with the heat from theelectric motors which generates vapor that must be vented. Vaporizedfuel cannot be used by the engine so it is lost to the atmosphere. Thesemultiple pumps and lines also take up internal fuel tank volume whichmay reduce mileage between fuel stops, an undesirable feature in avehicle such as a race car, an aircraft, a boat, etc.

In one embodiment, liquid reservoir system 100 may be shaped to fit invirtually any fuel tank design. It may contain an internal screen insertto keep the top and bottom separated and to give the liquid reservoirsystem a flatter profile on the tank floor. This insert also allows theliquid reservoir system to be folded or compressed together for ease ofinsertion into the generally smaller tank openings. The inlet port canbe designed to seal on any in-tank electric fuel pump. This can alsowork with pumps external to the tank.

In one embodiment, the profile of liquid reservoir system 100 may bedetermined by the vehicle application. For example, in racingapplications the liquid reservoir system may tend to occupy more of thebottom of the fuel tank than other applications.

In one embodiment, the liquid reservoir system may be completely orpartially contained in an enclosure. The enclosure may have an open orclosed top and may be mounted to the surface of the liquid reservoirsystem to keep more of the returned fuel closer to the pump. This mayshorten the supply path to the pump inlet and may reduce the associatedpressure drop.

In one embodiment, the fuel return line can be formed to be at anecessary and/or desired distance from the pump and then discharge fuelback towards the pump inlet.

In one embodiment, a plurality of liquid reservoir systems 100 may beused in a single fuel tank, covering different areas of the bottom ofthe fuel tank as needed and/or desired. These multiple reservoirs may bemolded with transfer passages or have connecting tubes, hoses, passagesand combinations thereof to transfer the liquid to the desired pick-uplocation.

In one embodiment, liquid reservoir system 100 may include one or morefittings for one or more liquid pick-up ports or for connecting one ormore liquid reservoir together, or to connect one or more liquidreservoir to one or more pumps.

Referring to FIGS. 6 and 7, liquid reservoir system 600 is illustratedaccording to one embodiment. Liquid reservoir system 600 may includesurround 610, which may comprise outer layer 615 and inner layer 620,one or more separating members 630, and liquid access port 640.Reservoir volume 650 is formed in the interior of inner layer 620.

In one embodiment, liquid reservoir system 600 may be provided in a fueltank (not shown) for a vehicle (e.g., car, truck, boat, motorcycle,snowmobile, aircraft, armored vehicle, etc.). Any suitable fasteningmechanism for fastening liquid reservoir system 600 to the fuel tank maybe used, including, for example, hooks, magnets (e.g., with a steeltank), hoses, clips, ties, studs, fittings, weighting, etc. In oneembodiment, liquid reservoir system 600 may be retained using rubberbladder dividers that may be molded in brackets and mounting points. Instill another embodiment, liquid reservoir system 600 may be held inposition by open cell foam blocks that may fill the remainder of thetank. In another embodiment, liquid reservoir system 600 may be retainedby a drop-in fuel module, or may be retrofitted to fuel systems.

In another embodiment, liquid reservoir system 600 may be mounted to adevice that follows the flow of liquid, such as a “swinging pickup” in atank that moves with the liquid. For example, liquid reservoir system600 may be suspended within the tank and allowed to move in one or moredirection in response to vehicle movement. In one embodiment, liquidreservoir system 600 may be weighted to assist in such movement.

In still another embodiment, the device may be retrofitted to anyexisting pick-up tubes on, for example, a gas sending unit. In stillanother embodiment, the device could be mounted directly on a pump.

In one embodiment, liquid reservoir system 600 may be shaped to conformto the shape of the tank in which it is disposed. In another embodiment,liquid reservoir system 600 may also include portions that extend inorder to be in substantially constant contact with liquid during liquidmovement. For example, portions of liquid reservoir system 600 mayextend perpendicular to the direction of movement so that at least someof liquid reservoir system 600 may maintain contact with a liquid duringcornering, turning, etc. Similarly, portions of liquid reservoir system600 may extend forward and backward (with respect to the direction ofmovement) in order to maintain contact with the liquid duringacceleration or braking.

An exemplary shape for liquid reservoir system 600 is provided in FIG.8.

In one embodiment, liquid reservoir system 600 may have one or more“windows” included therein. In one embodiment, the window may reduce thevolume of reservoir volume 650. Any size, shape, and/or number orwindows may be provided. In one embodiment, the size, shape, and/ornumber of windows may be selected based on the application.

In one embodiment, liquid reservoir system 600 may be provided on aninterior circumference of a tank in order to maintain contact with aliquid during inverted operation, such as for an aircraft.

In one embodiment, liquid reservoir system 600 may have any suitableconfiguration. For example, liquid reservoir system 600 may have an openlayer top and bottom to provide maximum surface area for fuelscavenging. In another embodiment, liquid reservoir system 600 may havea sealed top layer to draw fuel from the bottom surface. In anotherembodiment, liquid reservoir system 600 may have pleated side panels toallow for greater flexibility. In another embodiment, inner layer 620may comprise a plurality of materials. In still another embodiment,liquid reservoir system 600 may comprise multiple reservoirs, such as asmaller liquid reservoir system 600 inside a larger liquid reservoirsystem 600.

In still another embodiment, liquid reservoir system 600 may have acontoured shape for a specific flow control. Examples shapes include across shape, a “T”-shape, an “X”-shape, an “H”-shape, a “C”-shape, an“I”-shape, a “V”-shape, a star shape, a dog bone shape, a dog leg shape,a bowtie shape, a triangular shape, a round shape, an irregular shapes,a circular shape, an oval shape, an elliptical shape, etc. In addition,or instead, it may be a polygon, a cube, a box, a pyramid, flat,spherical, semi-spherical, cylindrical, round, thick, thin, long,skinny, etc. Any other shape or configuration that is conducive to beingfolded and inserted thru a small orifice may be used as is necessaryand/or desired.

In one embodiment, any of the shapes or configurations may be providedwith one or more cut-outs as is necessary and/or desired.

In one embodiment, the shape or configuration may be selected based onthe shape of the tank, the anticipated activity (e.g., high g-forces,low g-forces, etc.), installation ease (for tanks with large openings),etc.

Shapes that are more tailored to coverage and volume rather thaninstallation ease (for fuel cells and other tanks with large openings)

In another embodiment, liquid reservoir system 600 may include internalbaffles to specifically control flow within the reservoir system foroptimum delivery of the liquid to the pump inlet or port.

In one embodiment, liquid reservoir system 600 may include an externalreservoir. An example of such a system is illustrated in FIGS. 9 to 11.

Liquid reservoir system 900 includes external reservoir 910 that holds aliquid around the outlet to the pump. In one embodiment, externalreservoir 910, may be made of plastic or metal.

FIG. 9 is similar to FIG. 5B except that the top of external reservoir910 may be open (in FIG. 10 it has a cover) and external reservoir 910(e.g., 57R120) may be secured by adapter 920(e.g., B985010 ERL) andfastener 930 (e.g., nut B992410 ERL). Seals (e.g., Strat-o-seals27R1078) may be provided. In one embodiment, no adhesive is used; only aclamping force is used. The return fuel supply will typically over-flowthe reservoir due to the extra amount the pump supplies compared to theactual engine consumption.

Holes 940 may be provided on the floor of external reservoir 910 and maycommunicate to the surface of the media in an effort to retain more ofthe returned liquid available close to the outlet fitting. This reducesthe distance the liquid travels and helps maintain the wet media toextend the surface tension and thereby preventing air intrusion.

External reservoir 910 may be provided on any portion of the liquidreservoir system. In on embodiment, it may be closer to the side or areawhich the “G” forces are expected to move fuel. For example, for roadcourse racing, external reservoir 910 may be centered as the “G” forcesmay vary in multiple directions. For oval track racing, externalreservoir 910 may be located toward the outside edge. For drag racing,external reservoir 910 may be located toward the rear.

In still another embodiment, a return may be provided within liquidreservoir system 600 if aeration of the liquid being returned from theengine/fuel injectors or other device is below acceptable levels.

FIG. 11 depicts exemplary dimensions for external reservoir 910according to one embodiment. The dimensions provided are exemplary onlyand it should be recognized that the dimensions may vary according toapplication.

As shown in detail B, the perimeter of the external reservoir pressesagainst the outer surface of liquid reservoir system to direct fuelthrough the holes rather than letting “G” forces move the fuel away fromthe supply hose to the pump.

Any other suitable construction, orientation, and/or shape may be usedas necessary and/or desired.

In one embodiment, outer layer 615 may comprise a webbing of flexibleplastic material that may form an enclosure. In one embodiment, outerlayer 615 may comprise two sheets of material that may be sealed alongthe perimeter. Outer layer 615 may be used to maintain a shape forliquid reservoir system 600, and may provide coarse some filtering ofthe liquid, and may also protect inner layer 620 from damage.

In one embodiment, inner layer 620 may comprise a material that absorbsand/or wicks liquid from the surrounding environment. When wet, innerlayer restricts the passage of a gas, such as air, by providing abarrier against air intrusion until liquid is drawn from inner layer 620by, for example, a pump, or until such time that liquid is againavailable at outer layer for scavenging.

In one embodiment, inner layer 620 may comprise a filter material. Inone embodiment, inner layer 620 may have a filtration size rating of 5to 40 microns. In another embodiment, inner layer 620 may have afiltration size rating of between 10 to 30 microns.

Most OEM filter socks have 70 micron pore sizes. A few have 30 micronpore sizes. Both sizes, however, are too coarse for the liquid reservoirdisclosed herein (as it relates to fuel), as the pores are too large toseal properly to draw liquid from the reservoir. Depth media, the filtermaterial of choice for conventional inlet filters, typically do notreach the certain areas of the fuel tank.

In one embodiment, outer layer 615 and/or inner layer 620 may not beuniform in construction. For example, the portion of outer layer 615and/or inner layer 620 that may contact the liquid may comprise amaterial that is pervious to the liquid, while the portion that is notin contact with the liquid (e.g., the portion against the tank wall) maybe made of a different material. For example, a top surface of innerlayer 620 may have a filtration size rating of 10 microns, while abottom surface may have a filtration size rating of 30 microns. Usingthe smaller filtration size rating on the top surface of inner layer 620may be beneficial because the top surface may be exposed to air first asthe fuel in the fuel tank is consumed, and the smaller filtration sizerating will resist air intrusion into reservoir volume 650 better thanlarger filtration size rated media.

In one embodiment, the filtration size rating may vary depending on thetype of fluid, environmental conditions (e.g., temperature, pressure,etc.).

One or more separating members 630 may be provided. In one embodiment,separating members 630 may be flexible and may deform by a certainamount. In one embodiment, separating members 630 may not deform to thepoint where opposite sides of inner layer 620 touch substantially.Separating members 630 may have any suitable shape and may be made ofany suitable material. In addition, separating members 630 may have anysuitable orientation. The number, shape orientation, and/or material maybe selected for the environment in which liquid reservoir system 600 isused and/or the shape of liquid reservoir system 600.

In one embodiment, separating members 630 may be cylindrical, and may bemade of plastic.

In one embodiment, separating members hold surround 610 apart to createa reservoir of liquid within inner layer 620. This may extend the userof the reservoir before air intrudes. For example, under low fuelconditions, such as when the bulk of liquid reservoir system 600 isuncovered and exposed to air, the liquid within reservoir volume 650 maybe withdrawn by, for example, a fuel pump (not shown), causing surround610 to collapse on itself. Support members 630 prevent surround 610 fromcompletely collapsing on itself, acting like a spring, in order todeplete the reservoir capacity to as much as possible before airingestion. This may extend the surface tension of the liquid (e.g.,fuel) within reservoir volume 650 to delay the air intrusion.

When liquid reservoir system 600 is again surrounded by liquid, thereservoir function maintains its full capacity within reservoir volume650 by virtue of this webbing spring function. The velocity of theliquid through outer layer 615 and inner layer 620 is not restricted.

In one embodiment, the volume of the reservoir of liquid in liquidreservoir system 600 may be selected based on the pump flow in order todetermine an approximate “reserve time.” For example, the reserve timemay vary from a few seconds to a few minutes or more, depending on thesize of the liquid reservoir and the pump flow/volume.

Liquid access port 640 may be installed through one side of liquidreservoir system 600 based on, for example, vehicle dynamics, tankshape, liquid reservoir system 600 shape, etc. In one embodiment, a seal(not shown) may be provided on each side and compressed using, forexample, a jamb nut against the fitting flange Liquid access port 640may be connected to fuel pump (not shown) using a fuel line (not shown),such as a tube, hose, etc.

In one embodiment, liquid reservoir system 600 may be sized to occupythe entire “floor” of a fuel tank for two reasons. First, the largersize generally results in a larger reservoir volume 650, which means thefuel pump can draw fuel for a longer time before air intrusion.

Second, a large size generally results in a larger surface area andtherefore a lower velocity of fuel through outer layer 615 and innerlayer 620. This will extend the life of the boundary layer of fuelinside the media to before air intrusion.

An exemplary method for determining the proportions of the liquidreservoir system 600 is based on where a two gallon quantity is locatedin a specific fuel tank. For example, in this method, two gallons offuel is placed in the specific tank and then the tank is placed on a 30°angle to approximate a 1 G load and then measure the closest point tothe center of the tank. This may be repeated four times (once for eachside). The result may be a generally rectangular shape for the liquidreservoir system 600, which may be more than adequate for the typicalstreet vehicle. In this example, two gallons of fuel—which is typicallythe amount of residual fuel in the tank when the gage registers empty—isused; other amounts of fuel may be used as necessary and/or desired. Theamount may vary depending on vehicle type (e.g., truck, car, aircraft,etc.), application (e.g., normal driving versus racing), etc.

Although several embodiments are disclosed, it should be recognized thatthese embodiments are not necessarily exclusive. Some or all of thefeatures of one embodiment may be combined with some or all features ofother embodiments as necessary and/or desired.

EXAMPLES

The following examples of a liquid reservoir system is provided. Thisexample is illustrative only and does not limit the present disclosure.

A 1992 S/S 1500-Series pickup truck was equipped with the ARCA fuel cellin the bed with the following modifications:

1. Replace the bladder supplied in the ARCA fuel cell with theATL#FB222D 100 Series. There are no surge tanks inside.

2. Modify the flange to add −10×90° bent tube fuel outlet fittings and−8×90° bent tube return line fittings. Cap existing −10 welded supplyfitting.

3. Insert a liquid reservoir system in the bottom of the bladder withthe supply hose positioned on the passenger-side of the fuel cell.

4. −10×90° bent tube fuel outlet fittings and −8×90° bent tube returnline fittings were attached between the flange and the liquid reservoirsystem using the Earl's S/S Ultra-Flex hose.

5. Secure the return line fitting to discharge hose 1″ above the liquidreservoir system at the supply fitting.

6. Replace the yellow open cell foam with the black, large pore, opencell foam and install on top of the liquid reservoir system.

7. Install the Holley 12-1600, 12-848 regulator and the 162-570 (10micron) post filter. The regulator was positioned at the fuel cell toeliminate the need for a lengthy return line and ease of installation.

The test method was as follows:

1. Add approximately two gallons of premium 93 octane, pump gradegasoline to the fuel cell.

2. Drive an oval track at a safe, maximum speed until the engine dies.

3. Weigh the fuel cell assembly to determine the amount of unused fuelremaining in the fuel cell.

Results after Test #1:

Drive in the counter-clockwise direction

Dry fuel cell weighs 42.7 LBS.

Fuel cell after run-out-of-fuel test (ROF) is 43.9 LBS.

Remaining fuel is 0.2 gallons

ROF event:

Truck maintained 44-46 psi of fuel pressure for approximately ten laps.The last two laps, the fuel pressure began to fall (25-35 psi) and itwould stumble upon exit of turn 2 and 4, then finally die on the 12thlap. Fuel pressure was 22 psi when it died.

Re-priming after adding two gallons occurred after approximately fiveseconds (two cycles of the key to prime the pump).

Results after Test #2:

Drive in the counter-clockwise direction.

Dry fuel cell weighs 42.7 LBS.

Fuel cell after (ROF) is 44.2 LBS.

Remaining fuel is 0.25 gallons.

In the preceding specification, various preferred exemplary embodimentshave been described with reference to the accompanying drawings. Itwill, however, be evident that various modifications and changes may bemade thereto, and additional exemplary embodiments may be implemented,without departing from the broader scope of the invention as set forthin the claims that follow. The specification and drawings areaccordingly to be regarded in an illustrative rather than a restrictivesense.

What is claimed is:
 1. A liquid reservoir structure comprising: an outertop layer and an outer bottom layer being sealingly connected alongtheir periphery and defining an internal reservoir volume, an innerlayer disposed within the outer top layer and the outer bottom layer,wherein at least a portion of the outer layers and the inner layercomprise a permeable material, said outer layers and said inner layerhaving different filtration size ratings wherein said inner layer has afiner filtration size rating than said outer layers; at least oneflexible, permeable, and at least partially collapsible separatorpositioned between the outer top layer and the outer bottom layer withinthe internal reservoir volume, said separator capable of allowinginsertion and removal through a small opening of a fuel tank, the atleast one flexible separator maintaining a variable separation betweenthe outer top layer and the outer bottom layer; and an outlet port inthe top layer and communicating the internal reservoir volume, whereinthe outlet port is in communication with a vacuum source by a pump line;at least one standoff extending from above said outer top layer intosaid liquid reservoir structure and against an inner surface of saidinner layer to inhibit collapse of said liquid reservoir structure;wherein liquid is drawn into the internal reservoir volume through thepermeable material creating a boundary layer of liquid due to surfacetension of said liquid on said permeable material and further whereinsaid liquid is drawn through the outlet port; further wherein saidliquid reservoir structure is configured to be sized to increase areserve time.
 2. The liquid reservoir structure of claim 1, furthercomprising a plastic webbing surrounding the top layer and the bottomlayer.
 3. The liquid reservoir structure of claim 1, wherein thepermeable material comprises a filter material having a filtration sizerating between about 5 microns and 40 microns.
 4. The liquid reservoirstructure of claim 1, wherein filter material has a filtration sizerating between about 10 microns and 30 microns.
 5. The liquid reservoirstructure of claim 1, further comprising: an external reservoirpositioned proximate to the outlet port on an outer surface of the toplayer, wherein the external reservoir holds liquid around the outletport to the vacuum source.
 6. The liquid reservoir structure of claim 5,wherein the external reservoir comprises a plurality of holes on a lowerportion that is in contact with the outer surface of the top layer. 7.The liquid reservoir structure of claim 1, further comprising a liquidreturn that returns liquid from the vacuum source to an external surfaceof the liquid reservoir structure.
 8. The liquid reservoir structure ofclaim 1, further comprising a second liquid return.
 9. The liquidreservoir structure of claim 1, wherein the at least one flexibleseparator has a cylindrical shape.
 10. The liquid reservoir structure ofclaim 1, wherein the at least one flexible separator has ahalf-cylindrical shape.
 11. The liquid reservoir structure of claim 1,further comprising: at least one fastening mechanism for fastening theliquid reservoir structure to a tank.
 12. The liquid reservoir structureof claim 11, wherein the fastening mechanism comprises at least one of amagnet, a hook, a hose, a clip, a tie, a stud, a fitting, and a weight.13. The liquid reservoir structure of claim 1, wherein the outlet portis positioned in the liquid reservoir structure based on a force thatwill be applied to the liquid reservoir structure.
 14. The liquidreservoir structure of claim 1, further comprising: a second outlet portin the top layer and communicating the internal reservoir volume. 15.The liquid reservoir structure of claim 13, wherein the outlet port andthe second outlet port communicate to the vacuum source.
 16. The liquidreservoir structure of claim 1, further comprising: an externalreservoir provided on the top layer, the external reservoir incommunication with the vacuum source via at least one return line.
 17. Aliquid reservoir system, comprising: a tank having at least a lowersurface and an upper surface, a pump; and a liquid reservoir comprising:an outer top layer and an outer bottom layer, the outer top layer andthe outer bottom layer being sealingly connected along their peripheryand defining an internal reservoir volume, an inner layer disposedwithin the outer top layer and the outer bottom layer wherein at least aportion of the outer top layer and the outer bottom layer comprise apermeable material, and said outer layer and said inner layer havedifferent filtration size rates; at least one flexible, permeable, andat least partially collapsible separator positioned between the outertop layer and the outer bottom layer within the internal reservoirvolume, the at least one flexible separator maintaining a variableseparation between the outer top layer and the outer bottom layer whilealso allowing insertion and removal through a small opening of a fueltank; an outlet port in the outer top layer and communicating with theinternal reservoir volume, wherein the outlet port is in communicationwith the pump by a first pump line; and, at least one standoff extendingfrom above said outer top layer into said liquid reservoir structure andagainst an inner surface of said inner layer to inhibit collapse of saidliquid reservoir structure; wherein liquid is drawn into the internalreservoir volume through the permeable material creating a boundarylayer due to surface tension of said liquid on said permeable layer andfurther wherein said liquid is drawn through the outlet port; andwherein the liquid reservoir is positioned on the lower surface of thetank and the liquid reservoir is configured to be sized to increase areserve time.
 18. The liquid reservoir system of claim 17, wherein theliquid reservoir has a shape that conforms to the lower surface of thetank.
 19. The liquid reservoir system of claim 17, wherein the liquidreservoir has a shape that is adapted for an operating environment ofthe tank.
 20. The liquid reservoir system of claim 17, wherein the tankfurther comprises an opening, and the liquid reservoir is adapted to beintroduced to an interior of the tank through the opening.
 21. Theliquid reservoir system of claim 17, further comprising a return linefrom the pump, wherein the return line returns fluid from the pump toone of the top layer and the bottom layer of the liquid reservoir. 22.The liquid reservoir system of claim 17, further comprising a secondpump line for communicating a second port with the pump.
 23. The liquidreservoir system of claim 21, further comprising a second return linefrom the pump, wherein the second return line returns fluid from thepump to one of the top layer and the bottom layer of the liquidreservoir.
 24. The liquid reservoir system of claim 17, furthercomprising a fastening device for securing the liquid reservoir to thetank, the fastening device comprising at least one of a magnet, a hook,a hose, a clip, a tie, and a weight.
 25. The liquid reservoir system ofclaim 17, wherein at least a portion of the tank comprises an open-cellfoam material, the open-cell foam material applying a force tosubstantially maintain a position of the liquid reservoir.
 26. Theliquid reservoir system of claim 17, wherein the liquid reservoirfurther comprises a plastic webbing surrounding the outer top layer andthe outer bottom layer.
 27. The liquid reservoir system of claim 17,wherein the permeable material comprises a filter material having afiltration size rating between about 5 microns and 40 microns.
 28. Theliquid reservoir system of claim 17, wherein filter material has afiltration size rating between about 10 microns and 30 microns.
 29. Theliquid reservoir system of claim 17, wherein the liquid reservoirfurther comprises: an external reservoir positioned proximate to theoutlet port on an outer surface of the top layer, wherein the externalreservoir holds liquid around the outlet to the vacuum source.
 30. Theliquid reservoir system of claim 29, wherein the external reservoircomprises a plurality of holes on a lower portion that is in contactwith the outer surface of the top layer.
 31. The liquid reservoir systemof claim 29, wherein the at least one flexible separator has acylindrical shape.
 32. The liquid reservoir system of claim 29, whereinthe at least one flexible separator has a half-cylindrical shape. 33.The liquid reservoir structure of claim 1 wherein said liquid reservoiris sized proportionally to the reserve time.